Emergency Service Call in BFE - QUICK ELECTRICAL SERVICE PANEL SWAP

Brendan Lamothe

Key Takeaways

  • Sourcing specific panel components can be challenging.
  • Replacing an entire panel may be necessary for compliance.
  • Ensure all circuits are de-energized before beginning panel work.

Job Overview

Ranch Sale and Inspection Issue

The call you received concerns a ranch sale in Texas. The buyer's inspection report identified the absence of a dead front on a panel as a significant issue. While those familiar with ranch conditions might see this as a minor problem, safety regulations require dead fronts to prevent shocks. Both the buyer and seller agreed on the urgency of addressing this issue to proceed with the sale. The expectation is for you to solve this problem promptly because of the buyer’s concerns.

Urgency of the Electrical Repair

Your task started with locating a replacement dead front, which proved challenging due to limited availability in nearby supply houses. The urgency of the repair required rapid action. Without a suitable dead front, replacing the entire panel became necessary. Given the situation, and after obtaining approval from the power company, you proceeded to replace the main panel, ensuring that everything was safely disconnected first. In finding a replacement, the Siemens eight-space 200-amp panel was chosen for this job, complete with the necessary components to avoid extra trips for parts.

Sourcing a Dead Front

Challenges of Local Supply Houses

When you are working in rural areas like a ranch in Texas, sourcing a dead front panel can present unique challenges. Local supply houses generally focus on a limited selection of brands, often due to non-compete agreements. This means a supply house may specialize in a single brand such as Square D, GE, or Eaton. If you’re searching for a specific brand, like Siemens, your options might be limited.

If you find yourself in a position where you need a quick replacement, you may have to drive quite a distance or check multiple supply houses just to find the right fit. For instance, you may have to travel up to 45 minutes in several directions only to discover that the available options don't have the correct dimensions to match your requirements.

Panel Compatibility Issues

Compatibility with existing panels is crucial. If you locate a panel that appears suitable but does not fit due to size discrepancies or incompatible specifications, you are faced with a significant problem. Panels often vary by just a few inches, which can mean the difference between a successful or failed installation.

In instances where panel replacement is your only option, it is important to ensure compatibility with the existing electrical setup. In a pinch, you may need to purchase a completely new panel and retrofit it to the existing system. This can involve coordinating with the power company to manage disconnection safely and responsibly, especially when dealing with meters.

Navigating these challenges requires not only technical knowledge but also the flexibility to devise solutions under time constraints. While improvising temporary fixes, like adjusting or fabricating parts, can sometimes bridge gaps, having a backup strategy, like a secondary panel option or supplementary parts, is prudent.

Solution Implementation

Proposing a Panel Replacement

When you are faced with the issue of a missing dead front on an old panel in a remote location, finding an exact replacement can be challenging. Local supply houses may only offer certain brands and sizes, making it difficult to match your needs precisely. If an exact match is unavailable, your best course of action might be to propose a complete panel replacement.

The new panel should match the necessary specifications. In this scenario, using a Siemens panel that is eight spaces and 200 amps may be appropriate. Evaluate whether the replacement panel comes with essential elements, like ground buses, to avoid unnecessary trips back to supply houses.

During installation, handle PVC conduits with care, and ensure that none of them are damaged or need excessive force for removal or reconnection. If the existing system uses a feed-through panel, be cautious of how the conductors enter and exit, typically from the top and bottom.

Power Company Coordination

Coordination with the power company is a critical step, especially when you're about to perform tasks that typically fall under their jurisdiction, like removing or installing meters. Communication with the utility company is essential to ensure that your actions are compliant and safe. Confirming your professional status and willingness to assume liability is often necessary.

Before disconnection, ensure that the loads are entirely off to prevent hazardous electrical discharges or arcs. When reconnecting, the same diligence should be applied. Utilizing a common means of disconnection is crucial for safety and operational efficiency. Always verify that the main disconnect has been activated, ensuring a safe working environment for everyone involved.

Safety Precautions

Load Disconnection Before Meter Removal

When preparing to remove a meter, it's crucial to turn off the load to avoid potential hazards. Ensure that all breakers are switched off and the main disconnect is activated. This action prevents any active load from causing a dangerous arc or discharge when the meter is removed.

Imagine dealing with the disconnection of a 200 amp panel as opposed to a small 15 amp circuit. The risk is significantly higher, so thorough precautions are necessary. Always make certain that the premises are not under load when you proceed with meter disconnection. Additionally, be cautious of feed-through panels which may have connections that require special attention.

Master electricians may sometimes need to undertake responsibility for these tasks. If you're in this position, remember that dealing with live circuits should be avoided whenever possible. This care ensures safety for both you and the equipment involved.

Technical Insights

Understanding Feed-Through Panels

Feed-through panels serve a distinct purpose in electrical installations. In traditional panels, the breakers are located on the main bus bars. Conductors then exit from the sides to their destinations. In contrast, a feed-through panel features substantial lugs both at the top and bottom, allowing large conductors to enter from different directions. This design enables the panel to function as a main disconnect, efficiently de-energizing the primary panel and any subsequent panels along the line.

Advantages of Feed-Through Panels:

  • Provide a common means of disconnection for multiple panels.
  • Offer flexibility in installations by accommodating nearby circuits.

You might encounter scenarios where a panel’s installation was done without expected standards, such as nails used instead of screws. Situations like these might initially seem cumbersome but can sometimes provide ease in tasks like adjusting PVC conduits. This can be particularly beneficial when replacing or adjusting panels while dealing with multiple thick conductors entering from different directions.

Feed-through panels can include ground buses as standard, unlike some panels from other manufacturers where you might need to procure the ground bus separately. This feature is vital as it saves trips to supply houses, particularly when you're working in remote locations.

Deconstruction Challenges

Handling Non-Glued PVC

When working with panels that have non-glued PVC, you encounter unique challenges and opportunities. The absence of glue in PVC fittings provides increased flexibility in handling and deconstructing panel setups. Non-glued connections allow for the easy adjustment and removal of conduits, making the process of accessing conductors simpler and faster.

One advantage is that you can twist and adjust PVC fittings without damaging the infrastructure or needing significant replacements. This flexibility becomes crucial when dealing with heavy or cumbersome conductors that require strategic maneuvering for installation or removal.

To leverage these benefits:

  • Twist Fittings: Use the malleability of non-glued fittings to twist and realign PVC without structural concerns.
  • Access Conductors Easily: Simplify the handling of conductors by leveraging the non-permanent nature of the PVC connections.

Remember that while non-glued PVC offers ease, it’s vital to ensure proper reconnection and sealing if any adjustments are made, to maintain system integrity and safety.

Panel Installation Steps

Matching the Panel Size and Specs

When replacing a panel, selecting the correct size and specifications is crucial. You may come across panels with unique features, such as a feed-through design, which offers main disconnect capabilities and the option to support adjacent circuits. Ensure the new panel matches the old one in terms of amps and number of spaces; for example, an eight-space, 16-circuit, 200-amp panel. Remember: Some brands might not include crucial components like ground buses, so verify the contents of the new panel to prevent additional trips to the supply house.

Attention to Detail with Knockouts

Handling knockouts requires precision and care. Use the correct knockouts for your installation to avoid unnecessary alterations. Pulling too many or the wrong ones can lead to further complications, requiring additional materials and time. To maintain the panel integrity and meet client expectations, double-check your work before proceeding to the next step. Efficiently managing knockouts is not just a technical skill but an essential aspect of professional electrical work.

Grounding Considerations

Importance of Ground Bars in Panels

Ground bars are essential for the proper functioning and safety of electrical panels. They serve as the common return path for electric current and help prevent electrical shock by providing a path to earth for stray currents. In many panels, ground bars are included as part of the panel design, but there are some exceptions. For instance, panels from certain brands, like Schneider or Square D, may not always include ground bars by default. This omission can lead to extra trips to the supply house to obtain the necessary components.

Why Ground Bars Matter:

  • Safety: Ground bars protect against electric shock by ensuring that any fault current is safely directed to the ground.
  • Compliance: They ensure panels meet local and national electrical codes, which often require proper grounding for installation approval.
  • Functionality: Proper grounding helps maintain the reliability and functionality of the entire electrical system by reducing the risk of equipment damage.

Including a ground bar in every panel simplifies installation and improves safety. When purchasing panels, check to see if the ground bus is included. Obtaining all necessary parts from the start not only saves time but also ensures that the installation process is seamless and compliant with safety standards.